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Scania DC12 Operator - S Manual
Scania DC12 Operator - S Manual
Scania DC12 Operator - S Manual
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IMPORTANT INFORMATION
When work is being carried out on the engine such as adjusting drive belts, changing oil or
adjusting the clutch, it is important not to start the engine. The engine may be damaged and
! there is
A SERIOUS RISK OF INJURY
For this reason, always secure the starting device or disconnect a battery cable before working on
the engine.
This is especially important if the engine has a remote starter or automatic starting.
This warning symbol and text is reproduced beside those maintenance points where the risk of
injury is particularly great.
Operator’s Manual
DI12, DC12
EMS with S6/PDE
Industrial engine
opm_d12ind_en-GB01 1 920 785
Date of commissioning
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate
Foreword
This Operator’s Manual describes the handling and maintenance of Scania
DC12 and DI12 Industrial Engines with EMS S6/PDE injection systems.
The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder in-
line diesel type. These engines have turbochargers and charge air coolers; see
page 14.
Common applications are as power units in construction machines, generator
sets, earth-moving, railway and forestry machines as well as in irrigation
systems.
The engines can have different output and speed settings.
The normal output setting of the engine (performance code) is indicated on
the type plate, see page 14.
Note: Only standard components are described in the Operator’s
Manual. Please see the manufacturer’s instructions regarding
special equipment.
In order to obtain the best value and service life from your engine, there are
several points you should bear in mind:
- Read the manual before starting to use the engine. Even though you may
have experience of Scania engines you may find new information in this
Operator’s Manual.
- Follow the maintenance instructions. Good working order and service
life are ensured if maintenance is carried out according to the
instructions.
- In particular, read the safety information starting on page 6.
- Get to know your engine so that you know what it can do and how it
!
works. Important
- If necessary, contact an authorised Scania workshop. They have special During the warranty period,
tools, genuine Scania parts and staff with training and practical only genuine Scania parts may
experience of Scania engines. be used during service and
Note: Always use genuine Scania parts during service and repair so as repair; otherwise the warranty
to keep your engine in the best possible working order. will be invalidated.
The information in this manual was correct at the time of going to press.
However, we reserve the right to make alterations without prior notice.
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Contents
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Environmental responsibility
Scania has always been very much at the leading edge when it comes to
developing and producing engines which are as environmentally friendly as
possible.
Major progress has been made on reducing harmful exhaust emissions as
required to be able to meet the stringent environmental standards stipulated
on almost all markets.
At the same time, we have been able to maintain high quality in terms of
performance and operating economy for Scania Industrial and Marine
Engines.
To preserve these qualities throughout the entire service life of the engine, it
is important for the operator/owner to follow the instructions on running,
maintenance and the choice of fuel and oil as outlined in the manual.
Other efforts to preserve the environment we all share are possible by
ensuring that the person carrying out servicing and maintenance always
makes sure that environmentally hazardous waste after servicing and repairs
(oil, fuel, coolant, filters, batteries, etc.) is dealt with and disposed of in
accordance with applicable environmental standards.
Help protect our
On a number of pages, this Operator’s Manual contains specially highlighted environment!
text with instructions to help protect our environment during certain servicing
and maintenance work. Use a container to avoid spillage
when bleeding and changing
See example components.
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Certified engines
Emissions-certified engines have been approved in accordance with a special
certification standard. The certified engines supplied by Scania meet the most
stringent emissions standards which apply on European (EU) and non-
European (USA) markets.
Scania guarantees that all the engines it supplies of a certified type are
equivalent to the engine approved for certification.
The engine comes with a special certification plate which indicates the
certification rules (standard) to which the engine has been approved. See
page 14.
The following is required for the certified engine to meet emissions standards
once it has been commissioned:
- Servicing and maintenance must be carried out in accordance with the
instructions in this manual.
- Only genuine Scania parts are to be used.
- Injection equipment is to be serviced by an authorised Scania workshop.
- The engine must not be modified with equipment not approved by
Scania.
- Seals may be broken and setting data edited only once approval has been
granted by Scania in Södertälje. Changes may be made by authorised
personnel only.
- Changes which affect the exhaust system and intake system must be
approved by Scania.
Otherwise, the instructions in the manual in respect of running, care and
maintenance of the engine shall apply. The safety precautions described over
the next four pages must also be observed.
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Table of contents
General Warranty Provisions ......................... 6
Warranty Period ............................................. 7
Parts covered by the Warranty ....................... 7
General Warranty Limitations ....................... 8
Specific Warranty Exclusions ....................... 9
Customer Support ........................................... 9
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Warranty Period
This warranty shall apply for one of the following periods, whichever occurs
first:
• 3,000 hours of operation, or
• Turbocharger system
3. Exhaust manifold
4. Combustion chamber
• Piston
• Cylinder head
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Customer Support
In the event that you do not receive the warranty service to which you believe
you are entitled under the Warranty, or if you need additional support or
information concerning the Warranty, please contact:
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Safety information
General
This Operator’s Manual contains safety information which is important so as
to avoid both personal injury and damage to the product/other property. See
also page 1.
The text highlighted in text boxes on the right of a number of pages is
!
important for engine function and in order to avoid damage to the engine. If Important
these instructions are not followed, your warranty may be invalidated.
See example
Only use genuine Scania fuel
filters.
Similar text may also appear in the text column, and in this instance it will be
marked Note: or Important!.
The warning text found in text boxes on the right of a number of pages which
!
is marked with a warning triangle and starts with WARNING is extremely WARNING
important and warns you of serious engine faults or incorrect handling which
may lead to injury. Block the starting device when
working on the engine.
See example If the engine starts accidentally,
there is a
SERIOUS RISK OF INJURY.
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Starter spray
Refuelling Never use starting spray or similar as a starting aid.
There is a risk of fire and explosion when refuelling. This can cause an explosion in the intake manifold
The engine must be stopped and smoking is not and possible injury.
allowed.
Do not overfill the tank due to a risk of expansion,
and close the filler cap properly. Running
Use only fuel recommended in the service The engine must not be run in environments where
literature. Fuel of the wrong quality can cause the there is a risk for explosion as all of the electrical or
engine to malfunction or stop by preventing the mechanical components can generate sparks.
injection pump and injectors from operating as they Approaching a running engine always poses a safety
should. risk. Parts of the body, clothes or dropped tools can
This can cause damage to the engine and, possibly, get caught in rotating parts such as the fan and cause
injury. injury.
For personal safety all rotating parts and hot
surfaces must therefore be shielded as much as
Hazardous gases possible.
Only start the engine in a well ventilated area. The
exhaust fumes contain carbon monoxide and nitric
oxides, which are toxic.
If it is run in a enclosed space, there should be an
effective device to extract exhaust gases and
crankcase gases.
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Some chemicals, such as preservative oil, are also Extra equipment on the engine can alter the centre of
flammable. gravity, which is why you may need additional
lifting devices to balance the engine correctly and
Store chemicals and other materials which are lift it safely.
hazardous to health in approved containers, marking
them clearly and storing them where they are Never work underneath a suspended engine!
inaccessible to unauthorised persons. Always hand
in leftover or used chemicals to an authorised waste
disposal contractor. Batteries
The batteries contain a highly corrosive electrolyte
(sulphuric acid). Take care to protect your eyes, skin
and clothes when charging or handling batteries.
Wear protective gloves and goggles.
If the acid splashes on your skin, wash it off with
soap and copious amounts of water. If acid splashes
in your eyes, flush them immediately with copious
amounts of water and contact a doctor.
Dispose of used batteries through an authorised
waste disposal contractor.
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The engine type designation indicates engine type, size and applications in Type DI12 54A
code form. Engine No 6521399
Output. 331 kW 2200 rpm.
The type designation and engine serial number are specified on a type plate
Output kW rpm.
affixed to the right-hand side of the flywheel housing. The engine number is
also stamped on the right-hand side of the cylinder block. See the arrow in
illustration.
308 664
DI 12 54 A
Version
DC Supercharged diesel engine with air-cooled charge air cooler
DI Supercharged diesel engine with liquid-cooled charge air cooler
Application
A For general industrial use
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11 12
1, 2
3
10 9 5
8 7 6
18
13
17
16
15 14
The illustrations show a normal version of a DI12-engine.
Your engine may have different equipment from that illustrated.
1. Type plate 7. Oil filter unit 14. Fuel pump with hand pump
2. Engine number, stamped 8. Oil dipstick 15. Starter motor
into the cylinder block 9. Draining, engine oil 16. S6 control unit
3. Coolant pump 10. Oil cooler 17. Fuel filter
4. Automatic belt tensioner 11. Turbocharger 18. Charge air cooler
5. Draining, coolant 12. Oil filler
6. Oil filter 13. Hydraulic pump
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When the EMS control unit or the coordinator detects a fault, the diagnostics
lamp on the instrument panels(s) comes on, and it stays on as long as the fault
is active. At the same time, a fault code is generated which can be read off via
the coordinator on the diagnostics lamp in the form of a flash code when the
diagnostics switch is activated. A flash code may consist of a number of
different fault codes.
Diagnosis and troubleshooting using Scania EMS Display is described in the
Operator’s Manual for Scania EMS Instrumentation.
If the torque reduction function is activated, the amount of fuel and the engine
power output are reduced to 70%, and if the engine shutdown function is
activated, the engine is switched off at programmed alarm levels.
A separate PC-based diagnostics program is used to read off the contents of
the flash codes. For an in-depth analysis of fault codes, contact an authorised
Scania dealer.
Reading off the fault codes, and descriptions of these, are also covered in a
separate document in the workshop manual, Engine Management System
EMS-S6: Troubleshooting.
Only authorised personnel are allowed to carry out diagnostic procedures
and program changes.
The positions of the sensors which emit signals to the control unit are shown
in the illustrations on page 16.
See pages 20 and 22 for a description of how to read off flash codes.
See pages 21and 23 for a list of flash codes for the control unit and
coordinator.
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4
3
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3
4
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17 Oil temperature sensor faulty, or incorrect signal. 61 Incorrect control unit shutdown.
18 Oil pressure sensor faulty, or incorrect signal. 66 Shutdown due to coolant level.
23 Internal fault code in the coordinator. 69 Starter motor function interrupted or not activated.
28 Shutdown due to oil pressure. 85 Incorrect internal temperature in the control unit.
32 Incorrect parameters for limp home function. 87 Fault in control unit RAM.
33 Battery voltage incorrect or no signal. 88 Internal control unit fault: Memory fault.
43 CAN circuit faulty in the control unit. 93 Rotation speed sensors faulty or not connected.
47 Immobiliser function. Starter key code incorrect. 94 Shutdown due to high coolant temperature.
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111) Incorrect signal from the fine adjustment for the nominal engine speed signal.
112) Incorrect signals from the accelerator pedal sensor.
121) Incorrect signal from the resistor module for governor setting.
122) Incorrect signal from the resistor module for idle and fixed speed setting.
27 The signals from the RCB (Remote Control Box) switches are implausible.
32 Short circuit in the signal cable to the coolant temperature warning lamp.
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!
- Only antifreeze glycol should be used in the coolant as protection
against corrosion. We recommend only nitrite-free antifreeze glycols
with the following supplier designations:
WARNING
BASF G48 or BASF D542
- The concentration of glycol should be 30-60% by volume depending on Ethylene glycol and corrosion
the ambient temperature. 30% glycol by volume provides anti-freeze inhibitor can be fatal if
protection down to -16°C. See page 37. imbibed.
- Never top up with water alone or glycol alone! Fluid losses must always Avoid contact with the skin.
be replaced with pre-mixed coolant having the same glycol
concentration as that in the engine. If the glycol content drops, both anti-
!
freeze protection and protection against corrosion are impaired.
Note: A glycol concentration below 30% by volume will not provide
sufficient protection against corrosion. Glycol concentrations Important
higher than 60% do not improve anti-freeze protection and have
a negative effect on engine cooling capacity. The recommended glycols must
not be mixed with glycol
If there is no danger of freezing:
containing nitrite-based
- Only Scania Corrosion Inhibitor should be used in the coolant as corrosion inhibitor.
protection against corrosion. The correct corrosion inhibitor content is
8-12% by volume, and this must never drop below 8% by volume. The
inhibitor in Scania Corrosion Inhibitor is free of nitrites.
- First filling: Fill up the system with water + 10% by volume Scania
Corrosion Inhibitor. Use drinking water with a pH of 6-9.
!
Important
- Never top up with water alone or corrosion inhibitor alone!
Fluid losses must always be replaced with pre-mixed coolant: water Overdosing with Scania
+ 10% Scania Corrosion Inhibitor by volume. Corrosion Protection and mixing
with glycol can cause sludge to
form.
Coolant filter (not standard equipment)
Only coolant without inhibitor may be used. The use of coolant filters
!
increases the life of the coolant and reduces the risk of deposit corrosion.
Important
If a coolant filter has been fitted
it must not contain inhibitor.
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!
WARNING
Block the starting device when
working on the engine.
If the engine starts accidentally,
there is a
SERIOUS RISK OF INJURY.
Checks before running
Before running, carry out "Daily maintenance" as described in the
maintenance schedule, see page 31.
!
the battery master switch.
- Start the engine with the key on the control panel (SCP).
- S6: All lamps should go out after approximately 2 seconds when starting WARNING
the engine.
Never use starter spray or
similar agents to help start the
engine.
An explosion may occur in the
intake manifold with a risk of
personal injury.
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!
engine heaters or flame start devices should be used to avoid starting
problems and white smoke.
To limit white smoke, the engine should be run at low speed and under Important
moderate load. A moderate load on a cold engine gives better combustion and
faster heating than warming up with no load. The starter motor may only be
Avoid running it longer than necessary at idling speed. cranked for a maximum of
30 seconds. There is risk of
At temperatures below 0°C: overheating. Let the starter
Note: Only use starting aids recommended by Scania. motor rest for 30 seconds
between each start attempt.
- The starter motor may only be used for 30 seconds at a time. After that it
must rest for 30 seconds before attempting to start it again. Only 5
attempts may be made to start the engine. After that the starter motor
must rest for 15 minutes before the procedure can be repeated.
Note: If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held down until the oil pressure
has reached a sufficiently high level.
RUNNING
Check instruments and warning lamps at regular intervals.
Engine speed
The Scania tachometer is divided into different coloured sectors, as follows:
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Coolant temperature
Normal coolant temperature when the engine is running should be 70-90°C.
The S6 control system has the following alarm levels:
- If the temperature is high, 98°C-103°C, for a certain period (1 second),
S6 will send a CAN message which switches on the warning lamp and
diagnostics lamp via the coordinator.
- If the temperature exceeds 103°C, the warning lamp and diagnostics
lamps will come on. If torque reduction is activated, the control system
will reduce the fuel quantity to 70%. A fault code is generated in the
control unit.
- At temperatures exceeding 103°C and with engine shutdown activated,
the warning lamp and diagnostics lamp come on and the engine is
switched off. If the override function is activated, only torque reduction
takes place when this function is activated. A fault code is generated in
the control unit.
After an alarm, approved values should be registered for more than 2 seconds
to reset the alarm.
Excessively high coolant temperature can damage the engine.
If run for extended periods under an extremely light load, the engine may
have difficulty in maintaining normal operating temperature. However, the
temperature will rise to a normal level again when the load on the engine is
increased.
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Oil pressure
Maximum oil pressure:
warm engine running at a speed above 800 rpm 6 bar
Normal oil pressure:
warm engine at operating speed 3-6 bar
High lubricating oil pressure
Minimum oil pressure:
(above 6 bar) is normal when
warm engine running at a speed of 1,000 rpm 2.3 bar starting a cold engine.
The control system has the following alarm levels:
- at a speed of less than 1,000 rpm and an oil pressure of less than 1.0 bar
- at a speed of more than 1,000 rpm and an oil pressure of less than 2.3 bar
for longer than 5 seconds.
The following functions are available if there is an alarm:
- Alarm which only switches on the warning lamp and diagnostics lamp.
- Alarm which switches on the warning lamp and diagnostics lamp as
well as torque reduction if this function is activated (70% of fuel
quantity).
A fault code is generated in the control unit.
- Alarm which switches on the warning lamp and diagnostics lamp. The
engine is switched off if engine shutdown is activated. If the override
function is activated, only torque reduction takes place when this
function is activated.
A fault code is generated in the control unit.
After an alarm, approved values should be registered for more than
1 second to reset the alarm.
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!
Important
There is danger of turbocharger
Stopping the engine damage and post boiling if the
engine is stopped without
1. Run the engine without a load for a few minutes if it has been run cooling.
continuously with a heavy load.
!
2. Stop the engine with the stop button or the starter key (depending on
version). Keep the stop button depressed until the engine has stopped
completely.
Important
3. Set the control switch to the "0" position.
The power must not be switched
4. Engines with battery master switch: Switch the power off with the
battery master switch.
off before the engine has
stopped.
Note: 10 prohibited engine stops will cause torque reduction (70% of
fuel quantity). To reset the engine, switch off the engine once in
!
the prescribed manner.
WARNING
Block the starting device when
Checks after running working on the engine.
If the engine starts accidentally,
- Check that the power is cut from the battery master switch and that the there is a
control switch is in the "0" position. SERIOUS RISK OF INJURY.
- Fill the fuel tank. Make sure that the filler cap and the area round the
filler opening are clean to avoid contamination of the fuel.
- If there is a risk of freezing, the cooling system must contain enough
glycol. See pages 24 and 37.
- At temperatures below 0°C: prepare for the next start by connecting the
!
engine heater (if fitted). Important
Coolant should be topped up
when the engine is stopped after
the first start.
!
WARNING
The system is pressurised.
Major risk of burns.
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Maintenance
The maintenance programme covers 20 points, divided into the following
main groups:
Lubricating oil system . . . . . . . . . . . . . . . . . page 28
Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 32 !
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . page 38 WARNING
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . page 40
Electrical system, batteries, etc. . . . . . . . . . . page 42 Block the starting device when
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . page 44 working on the engine.
If the engine starts accidentally,
The maintenance points are divided into intervals as follows: there is a
Daily maintenance SERIOUS RISK OF INJURY.
Maintenance before the first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation (carried out at 200, 400,
600, 800, etc. hours)
Periodic maintenance every 400 hours of operation (carried out at 400, 800,
1,200, 1,600, etc. hours)
Periodic maintenance every 1,200 hours of operation (carried out at 1,200,
2,400, 3,600, etc. hours)
Periodic maintenance every 2,400 hours of operation (carried out at 2,400,
4,800, etc. hours)
Periodic maintenance every 4,800 hours of operation (carried out at 4,800,
9,600 etc. hours)
Annual maintenance
Maintenance every 5 years
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Maintenance schedule
First Interval At least
time at
Every 5 years
First start
Annually
1,200 h
2,400 h
4,800 h
400 h
200 h
400 h
Daily
Lubricating oil system, page 28
1. Checking the oil level z z
2. Oil change z1 z
3. Cleaning the lubricating oil cleaner. z1 z
4. Renewing the oil filter z1 z
Cooling system, page 32
5. Checking the coolant level z
6. Checking the coolant z z3 z
7. Cleaning the cooling system z1 z
Air cleaner, page 38
8. Test reading of vacuum indicator z
9. Cleaning the coarse cleaner z1 z
10. Cleaning or renewing the filter element z2 z
11. Renewing the safety cartridge z z
Fuel system, page 40
12. Checking the fuel level z z
13. Changing the main filter and water separating filter z1 z
Electrical system, page 42
14. Checking the electrolyte level in batteries z z z
15. Checking the state of charge in batteries z z z
16. Cleaning the batteries z z
17. Checking the coolant level monitor z z
Miscellaneous, page 44
18. Checking the drive belt z z z
19. Check for leaks, rectify as necessary z
20. Checking and adjusting valve clearances z z
21. Checking and adjusting the unit injector rocker arms z z
22. Renewing (or cleaning) the closed crankcase ventilation z
valve
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Oil analysis
Some oil companies can offer analysis of the engine oil. Such analysis
measures the oil’s TBN (Total Base Number), TAN (Total Acid Number),
fuel dilution, water content, viscosity and the quantity of wear particles and
soot in the oil.
The result of a series of analyses is used as the basis for establishing a
suitable oil change interval.
If the conditions are changed, a new oil analysis programme must be carried
out to establish the new change interval.
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 10W-30
SAE 15W-40
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1. Daily:
Checking the oil level
Note: Before checking oil level: Leave the engine switched off for at
least 1 minute.
- The correct level is between the marks on the dipstick. Top up when the
level is at the lower mark.
- For the correct oil grade, see page 32.
1 dm3 = 1 litre
!
WARNING
The oil may be hot.
Wear protective gloves and Help protect our
goggles. environment!
Use a container to avoid spillage
Maximum angles of inclination during operation when changing the oil. Dispose
Maximum permissible angles during operation vary, depending on the type of of used oil through an
oil sump, see illustration. authorised waste disposal
Note: The specified angles may only occur intermittently. contractor.
25°
25°
35° 35°
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- Clean the cover. Unscrew the nut and remove the cover.
!
WARNING
Open the cover carefully. The
oil may be hot.
- Lift out the rotor and wipe the outside. Unscrew the rotor cover nut
about one and a half turns.
- Hold the rotor and tap lightly on the rotor nut with a plastic mallet or
against the workbench, so that the rotor bowl comes loose from the
bottom plate. Never strike on the rotor directly as this may damage the
bearings.
- Scrape off the deposits from the inside of the rotor cover. If there are no
deposits, this indicates that the cleaner is not working properly.
- If the deposits are thicker than 28 mm: clean more often.
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- Check that the shaft is not loose. If it is loose, use locking compound
561 200 and torque tighten to 34 Nm using tool 98 421.
Functional inspection
The rotor rotates very fast and should continue to rotate when the engine has
stopped.
- Stop the engine when it is warm.
- Listen for a whirring sound from the rotor or feel whether the cleaner
housing is vibrating.
The rotor normally continues spinning for 30-60 seconds after the engine has
stopped.
If not: dismantle and check.
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5. Daily:
Checking coolant level !
WARNING
- Open the expansion tank filler cap and check the coolant level.
- Correct level: (Scania plastic expansion tank)
Open the cap carefully.
Water and steam can spray out.
- Cold engine: The coolant should be level with the bottom of the
filler neck.
- Hot engine: The coolant should be about 25 mm above the
lower edge of the filler hole.
- Other types of expansion tank according to the instructions of the fitter.
- Top up the coolant as necessary; see point 6.
Note: When filling large amounts of coolant: !
Never pour cold coolant into a hot engine. This could crack the
cylinder block and cylinder head.
Important
Always top up with pre-mixed
coolant.
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!
- The table shows the temperature at which ice starts to form. The engine
will freeze and break at appreciably lower temperatures; see diagram.
- Ice forming in the coolant often causes malfunctioning without any risk Important
of damage. The engine should not be subjected to heavy loads when ice
starts to form. The recommended glycols must
not be mixed with glycol
Note: The coolant should be changed when the cooling system is
cleaned: every 4,800 hours or at least every 5 years. containing nitrite-based
corrosion inhibitor.
Important! If a coolant filter is used in the cooling system it must not Risk of sludge build-up and
contain an inhibitor. reduced cooling capacity.
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A
Glycol % by
15 20 25 30 35 40 45 50 60
volume Cooling system
Ice slush starts to volume, dm3
-6 -9 -12 -16 -22 -27 -36 -46 -55
form at °C
5 6 8 9 11 12 14 15 18 30
6 8 10 12 14 16 18 20 24 40
8 10 13 15 18 20 23 25 30 50
9 12 15 18 21 24 27 30 36 60
11 14 18 21 25 28 32 35 42 70
12 16 20 24 28 32 36 40 48 80
14 18 23 27 32 36 41 45 54 90
15 20 25 30 35 40 45 50 60 100
Glycol dm3 17 22 28 33 39 44 50 55 66 110
(litres) 18 24 30 36 42 48 54 60 72 120
20 26 33 39 46 52 59 65 78 130
21 28 35 42 49 56 63 70 84 140
23 30 38 45 53 60 68 75 90 150
24 32 40 48 56 64 72 80 96 160
26 34 43 51 60 68 77 85 102 170
27 36 45 54 63 72 81 90 108 180
29 38 48 57 67 76 86 95 114 190
30 40 50 60 70 80 90 100 120 200
A = Area to be avoided. Only for calculating glycol mix.
Coolant freezing point (when ice starts to form) for different glycol mixes
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c)
Checking the corrosion inhibitor !
There must always be sufficient corrosion protection (inhibitor) in the coolant WARNING
to protect the cooling system against corrosion.
Corrosion inhibitor is highly
If there is no danger of freezing, only Scania Corrosion Inhibitor should be dangerous if ingested and can
used in the coolant.
prove fatal.
The inhibitor in Scania Corrosion Inhibitor is free of nitrites. Avoid contact with the skin.
The correct corrosion inhibitor content is 8-12% by volume.
- Topping up with 1.0% Scania Corrosion Inhibitor by volume should be
done after every 2,400 hours of operation.
- Never top up with water alone or corrosion inhibitor alone!
!
Fluid losses must always be replaced with pre-mixed coolant: water Important
+ 10% Scania Corrosion Inhibitor by volume. Mixing with glycol or the use of
Note: The coolant should be changed when the cooling system is too much corrosion protection
cleaned: every 4,800 hours or at least every 5 years. can lead to build up of sludge
and reduced cooling capacity.
!
Important
If a coolant filter has been fitted
it must not contain inhibitor.
Changing coolant
1. Remove the filler cap from the expansion tank.
2. The coolant is drained at two points:
- the lowest point of the cylinder block, see illustration.
- the lowest point of the cooling system.
3. Close the cocks.
4. Top up with coolant through the expansion tank’s filler hole.
Mix coolant as described on page 35.
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1. Charge air
cooler element 3
2. O-ring
3. Sealant 816 064
4. Intake manifold
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Internal cleaning
Removing oil and grease
- If possible, run the engine until it has reached operating temperature and
!
then drain the cooling system.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with liquid dishwasher
WARNING
detergent designed for household use.
Concentration 1% (0.1/10 l). When handling cooling system
detergent:
- Run the engine until warm for about 20-30 minutes. Do not forget the
cab heating system (if fitted). read the warning text on the
containers.
- Drain the cooling system.
- Fill the system again using clean, hot water and run the engine for about
20-30 minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with new coolant according to the specification on
page 35. Help protect our
environment!
Removing deposits Use a container to avoid spills
- If possible, run the engine until it has reached operating temperature and when changing the coolant.
then drain the cooling system. Dispose of used coolant through
- Remove the thermostats. an authorised waste disposal
contractor.
- Fill the system with clean, hot water mixed with some of the radiator
cleaning agent available on the market which is based on sulphamic acid
and contains dispersing agents. Follow the manufacturer’s instructions
for the concentration and cleaning period.
- Run the engine for the specified time and then drain the cooling system.
- Refill the system with hot water and run the engine for about
20-30 minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with coolant according to the specification on
page 35.
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Air cleaner
8. Daily:
Test reading of vacuum indicator
If the red indicator bar is entirely visible, change or clean the air cleaner filter
element, point 10. This is particularly important if the engine is run at high
loads and high speed.
!
9. Every 200 hours: Important
Cleaning the air cleaner’s coarse The coarse cleaner must always
cleaner be fitted in an upright position.
!
the inside.
Note: This filter element must not be washed with water.
WARNING
2 Never start the engine without
1 3
the air filter.
There is a risk of injury or
engine damage.
1. Cover
2. Filter element
3. Filter house
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Check
- Insert a torch into the element and check from the outside that there are
no holes or cracks in the filter paper.
- Renew the filter element if it has the slightest damage. Danger of engine
damage.
Assembly
1. Assemble the air cleaner in reverse order.
2. Reset the vacuum indicator by pressing the button.
1. Safety cartridge
Air cleaner with safety cartridge
!
Important
Never clean the
safety cartridge.
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Fuel system !
12. Daily: Important
Observe the utmost cleanliness
Checking fuel level when working on the fuel
- Top up with fuel if necessary. system.
- If the tank has been run dry, bleed the fuel system, see point 13. There is a risk of engine
malfunction and damage to the
injection equipment.
1. Shut-off cock
2. Filter
3. Drain valve
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• After renewing the fuel filter, it will take approximately 170 strokes. 3
1
• Approximately 150 strokes are required to bleed the fuel manifold.
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Electrical system
14. Every 200 hours: !
WARNING
Checking the electrolyte level in Avoid naked flames or sparks
batteries near the batteries.
1. Unscrew the plugs and check the electrolyte level in all cells. When the batteries are charged,
2. Top up with distilled water until the level is 10-15 mm above the plates. oxyhydrogen gas is formed
which is flammable and
explosive.
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Miscellaneous
18. Every 1,200 hours:
Checking drive belt
- If the drive belt (1), which is a poly-V belt, is worn or damaged it must
be renewed.
- Also check that the automatic belt tensioner (2) is in proper working
order and keeps the drive belt correctly tensioned.
- On installations with dual belt circuits, the second belt circuit has two
drive belts with one manual belt tensioner. These drive belts should be
tensioned to 20 Nm ±2 Nm as illustrated.
m
N
2
+
-
m
N
20
307 938
Nm
2
+
-
Nm
20
307 939
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19. Daily:
Look for leakage, rectify as necessary
- Start the engine.
Help protect our
- Check for oil, coolant, fuel, air and exhaust leaks. environment!
- Tighten or renew leaking connections. Check the overflow holes (1)
(below the side covers) which show whether the O-rings between the
Take care to ensure that any
cylinder liners and crankcase are leaking, see figure. leaks do not cause pollution.
a) If coolant is running out, the O-ring is leaking.
!
b) If lubricating oil is running out, the liner shelf is leaking.
- Check that the coolant pump drain hole (2) is not clogged, see figure. If
there is a leak, renew the pump seal or the complete coolant pump. Important
A small amount of leakage from the overflow holes during the engine
running-in period is normal. (Sealing rings and O-rings are lubricated If serious leakage occurs,
with soap or oil when fitted). contact your nearest Scania
workshop.
- This leakage normally stops after a time.
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Readings can be taken from the flywheel through covers in the flywheel
housing either from above or underneath depending on access when fitting.
Up or down is shown on the flywheel. Both openings are fitted with a cover at
delivery.
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Order of adjustment
- Turn the flywheel counterclockwise so that the marks on the flywheel 1
can be seen in the lower opening in the flywheel housing (depending on
which opening the reading is to be taken from). Refer to table.
- Measure the valve clearance with a feeler gauge and adjust the valves as
2
per the order of adjustment in the table below. Correct valve clearances
are also given on the instruction plate on one of the rocker covers. 3
- Checking and adjustment of the rocker arms for the PDE injectors
should be done together with the valve clearance check/adjustment. See 4
step 21.
- If it is not possible to take a reading in one of the covers, observe the 5
valve overlap, turn the flywheel counterclockwise 120° (1/3 turn) at a
time and adjust the valves according to the table below and the unit
injectors as described on the next page. 6
FLYWHEEL
120° 5 2
240° 3 4
120° 2 5
240° 4 3
Mark on flywheel
Valve overlap on Adjust the valves
(reading taken through the
cylinder on cylinder
upper opening)
TDC Up (0°) 1 6
300° 5 2
60° 3 4
TDC Up (360°) 6 1
300° 2 5
60° 4 3
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Readings can be taken from the flywheel through covers in the flywheel
housing either from above or underneath depending on access when fitting.
Up or down is shown on the flywheel. Both openings are fitted with a
blanking piece on delivery; see illustration on page 46.
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Order of adjustment
Turn the flywheel counterclockwise so that the marks on the flywheel can be
seen in the lower opening in the flywheel housing (depending on which
opening the reading is to be taken from). Refer to table.
120° 5 4
240° 3 1
120° 2 3
240° 4 6
TDC Up (0°) 1 2
300° 5 4
60° 3 1
TDC Up (360°) 6 5
300° 2 3
60° 4 6
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PDE31:
1. Firstly, measure the distance (A) between plane (a) and the top edge of
the valve spring washer on the unit injector using a digital sliding
calliper. See figure.
2. Dimension (A) should be 66.9 mm for PDE31 (dimension B=36.5 mm).
3. The dimension is adjusted by undoing the lock nut and screwing the
rocker arm adjusting screw (1) to the correct measurement.
WARNING! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The
spring is pre-tensioned and can cause personal injury if it is
released.
4. Position setting tool 99 414 with the metal plate around the injector
spring.
5. Finely adjust dimension (A ) by simultaneously using a finger to sense
that the small piston (2) is level with the flat upper surface of the tool. It
is possible to feel differences of less than a tenth of a millimetre.
6. If the setting tool is not available, a digital sliding calliper can also be
used for fine adjustment. The rocker position is adjusted using the
adjusting screw to 66.9 +/-0.1 mm as stated above.
7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.
Note: No further checking or adjustment of the unit injector, such as
checking the opening pressure, must be done. If an injector is
defective, the whole injector must be replaced.
99 414 66.9
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PDE32:
1. Firstly, measure the distance (A) between plane (a) and the top edge of
the valve spring washer on the PDE injector using a digital sliding
calliper. See figure.
2. Dimension (A) should be 69.9 mm for PDE32 (dimension B=38.8 mm).
3. The dimension is adjusted by undoing the lock nut and screwing the
rocker arm adjusting screw (1) to the correct measurement.
WARNING! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The
spring is pre-tensioned and can cause personal injury if it is
released.
4. Position setting tool 99 442 with the metal plate around the injector
spring.
5. Finely adjust dimension (A ) by simultaneously using a finger to sense
that the small piston (2) is level with the flat upper surface of the tool. It
is possible to feel differences of less than a tenth of a millimetre.
6. If the setting tool is not available, a digital sliding calliper can also be
used for fine adjustment. The rocker position is adjusted using the
adjusting screw to 69.9 +/-0.1 mm as stated above.
7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.
Note: No further checking or adjustment of the unit injectors, such as
checking the opening pressure, must be done. If an injector is
defective, the whole injector must be replaced.
99 442 69.9
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Preservative fuel
- Use diesel fuel oil mixed with Lubrizol 560H or equivalent.
- Mix 1 cm3 (ml) Lubrizol 560H in 10 dm3 (l) of fuel.
!
HANDLING LUBRIZOL 560H
Hazardous!
Contains aromatic hydrocarbons
Use spot extractors where there is a danger of vapour build-up.
Wear protective gloves and goggles when handling Lubrizol. Do not use contaminated clothing.
If it gets in your eyes: Rinse with a gentle stream of water (at least 15 minutes). Seek medical attention.
If it gets on your skin: Wash the affected area with soap and water.
If inhaled: Fresh air, rest and warmth.
Flammable: Fire class 2A. Flashpoint +27°C.
In the event of fire: Extinguish with carbon dioxide, powder or foam.
Storage: In well-sealed receptacle in a dry, cool place. Keep out of reach of children.
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Preservative oil
Suitable preservative oils are available from most oil companies.
For example Dinitrol 40 or equivalent.
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Batteries !
Remove the batteries for trickle charging at the battery charging station. WARNING
(Does not apply to batteries which according to the manufacturer do not
require any maintenance). The same applies to short-term storage, even if the Wear gloves and protective
engine has not been prepared for storage as above. goggles when charging and
handling batteries.
Storage The batteries contain a highly
After the preparations, the engine should be stored in a dry and warm place corrosive acid.
(room temperature).
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Technical data
General DC12 DI12
Number of cylinders 6 in line
Cylinder diameter mm 127
Piston stroke mm 154
Displacement dm3 (litres) 11.70
No. of main bearings 7
Firing order 1-5-3-6-2-4
Compression ratio 18:1
Engine direction of rotation viewed from rear Counterclockwise
Fan direction of rotation viewed from front Clockwise
Cooling Liquid
Valve clearances, cold engine
intake valve mm 0.45
outlet valve mm 0.70
Weight, without coolant or oil kg 1,065* § 995
*With charge air cooler, radiator, expansion tank and
pipes
Power see "Engine record card"
Lubrication system
Maximum oil pressure
(warm engine at a speed above
1,000 rpm bar (kp/cm2) 6
Normal oil pressure
(hot engine at operating speed) bar (kp/cm2) 3-6
Minimum oil pressure
(hot engine 1,000 rpm bar (kp/cm2) 1.0
Oil capacity, see page 33
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Cooling system
Number of thermostats 1 (dual thermostat)
Thermostat, opening temperature °C 75
Coolant temperature:
system at atmospheric pressure °C 70-93
system at overpressure °C 70 - approximately 100
Capacity, including radiator, engine and expansion tank
and, for DI12, also charge air cooler
with 0.75 m2 radiator dm3 (litres) 54 56
2
with 1.0 m radiator dm3 (litres) 59 61
2
with 1.2 m radiator dm3 (litres) 63 65
Electrical system
System voltage V 24
Alternator, current A 65 or 100
Starter motor output kW (hp) 6.7 (9.1)
Monitors, threshold values:
oil pressure monitor bar (kp/cm2) 1.0 ± 0.15
temperature monitor °C Stamped on hexagonal part of monitor
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Fuel
Diesel fuel oil
The composition of the diesel fuel oil has a great influence on the functioning
and the service life of the engine and the injection system. The engine output
and exhaust emissions are also dependent on the fuel quality. The
requirements and testing standards for the most important properties are
described in the workshop manual in sections which can be ordered from
Scania dealers or directly from Scania. Scania’s address is printed on the
cover.
Diesel fuel must comply with the following standard: EN 590 (European
standard).
The table below shows the requirements for some of the most important
properties.
Property Requirements
Viscosity at 40°C 2.0-4.5 mm2/s (cSt)
Flashpoint 56°C
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!
At temperatures lower than those specified for the diesel fuel, paraffin wax
may precipitate from the fuel and block filters and pipes. The engine can then
lose power or stop.
WARNING
The diesel fuel is adapted for use in the specific climate of each country. If a
vehicle or an engine is to be operated in a temperature zone with lower It is not permitted to mix
temperature than normal, first identify the temperature properties of the fuel kerosene with diesel fuel that is
concerned.
already adapted for the climate
The properties of the fuel when cold can be improved by adopting one of the concerned. The unit injectors
following measures before the temperature drops: can fail. All use of paraffin
- If the fuel concerned cannot cope with the expected temperatures, and other than kerosene is
diesel fuel is not available with the correct temperature properties, we forbidden, as it causes engine
recommend that an electric fuel heater is installed as a preventative damage.
measure.
- The low temperature properties of diesel fuel may be improved by
adding kerosene as a preventative measure. Maximum 20% may be
added. When refuelling, the kerosene should be added first, so that it
mixes thoroughly with the diesel fuel.
Note: It is prohibited to use kerosene in engine fuel in
!
some countries. Important
- To prevent water in the fuel from freezing and forming ice, a maximum It is not permissible to mix
of 0.5-2% alcohol (isopropanol) may be added. petrol with diesel fuel. In the
Drain fuel tanks and drain or renew fuel filters regularly. long term, petrol may cause
wear to the unit injectors and at
worst it may also cause damage
to the engine.
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Alphabetical index
Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Scania Assistance
Wherever you are you can always get assistance from our service
organization, Scania Assistance. All day, every day of the year. Using Scania
Assistance is free, but the cost of repairs, spare parts and help from
mechanics will be debited.
Always call your own country!
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